Process for the treatment of ores and substances.



F. L. MCGAHAN. PROCESS FOR THE TREATMENT OF ORES AND SUBSTANCES.

APPLICATION FILED FEB- 26. 1914, I 1 ,239,282. Patented Sept. 4, 1917.

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F. L. McGAHAN.

PROCESS FOR THE TREATMENT OF ORES AND SUBSTANCES.

APPLICATTON FILED FEB. 26, T9T4- '1 ,239,282 Patented Sept. 4, 1917.

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F. L. McGAHAN.

PROCESS FOR THE TREATMENT OF OR ES AND SUBSTANCES.

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Frederick L. Mafia]? F. L. McGAHAN.

PROCESS FOR THE TREATMENT OF ORES AND SUBSTANCES. APPLICATION FILED FEB. 26. 1914.

1 39,282 Patented Sept. 4, 1917,

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F. L. McGAHAN. PROCESS FOR THE TREATMENY 0F ORES AND SUBSTANCES.

PatentedSept. 4, 1917.

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In van i017 ederztflLMG'czhan ,C w M\ 2 II I? FREDERICK -L. McGAI-IAN, OF LOS ANGELES, CALIFORNIA.

EROCESS FOR THE TREATMENT OF ORES AND SUBSTANCES.

Specification of Letters Patent.

Patented Sept, 4, 1917.

Application filed. February 26, 1914. Serial No. 822,234.

T 0 all whom it may concern:

Be it known that I, FREDERICK L. Mo- GAHAN, a citizen of the United States, residing at Los Angeles, in the county of Los Angeles and State of California, have invented a new and useful Process for the Treatment of Ores and Substances, of which the following is a specification.

My invention relates to a process for smelting ores, alloying metals extracted from the ores, refining various substances, and extracting all of the by-products from any substance capable of reduction. I

An object of my invention is to roast, under agitation, a number of different grades and character of ores at the same time in different smelting chambers, each of which smelting chambers are provided with an associated combustion chamber in which a dilferent temperature may be maintained during the smelting process, for the extraction from the ores of different metals and substances.

Another object is the maintenance of an artificial vacuum draft system connected with a stack which is common to all of the smelting chambers, products of'combustion from the combustion chambers, and the gases liberated from the substances roasted are drawn off, condensed and superheated after first having been thoroughly mixed;

Another object is the provision for acomprehensive circulating water system, by means of which the grates in the roasting chambers and certain other elements of the furnace may be water cooled during the smelting process, system utilized for the formation and supply of steam to the furnace, pumps, and other machinery of the plant.

Another object is the provision for drawing oif through the stack of all of the unconsumed gases and substances, subjecting them to a condensation process by means of which the volatilized gases may beseparated from the heavier substances, and by a mixture with steam and liquid fuel and passing them through a series of retorts in the lining of the combustion chambers, superheated and stored in suitable receptacles, from which they may be in the furnace, and the heavier gases and substances thus separated, subjected to agiand through which the,

and the same water cooling drawn off and used again tation, freezing by the use of the ammonia gases and a gravity separation process, by means of which the dead oils and sediment,

largely composed of magnesia, silicates and like particles, are separated from their liquids and the liquids and solid matter separately drawn off, and the finer metals by an electro-plating process accumulated and their values weighed on the scales from which the plates are suspended; the water being stored in suitable tanks for future use in the plant and the sediment formed into briquets for future refining and separation into their constituent elementsJ Another object is to provide for casting the bars of bullion drawn from the combustion chambers, in a vacuum pit for rendering the bars free from air holes and defects.

Another object is to adapt the same plant in which the smelting of the raw ores is done, to use in refining the substances extracted from the ores, and for alloying the metals so extracted.

In general, it is my object to provide a process whereby all of the substances from any matter whatsoever, may be separately extracted and refined, the volatile -gases drawn off, and utilized, where possible, in the operation of the plant, or otherwise stored in suitable receptacles provided for the purpose; the overheating of the metallic parts of the furnace is prevented in the roasting process; the presence of nitrogen in the gases and in the combustion chambers is eliminated; the presence of atmospheric air in the combustion chambers is practically impossible; a generally economical method of operating the plant and in the useof fuels and other elements contributing to the successful operation of the plant; and the obtaining of values from ores and substances,

which have hithertobeen impossible, under the prevailing methods. 7

Other objects may appear in the subjoined detailed description of the plant as illustrated in the accompanying drawings in which: V

Figure 1 is a front elevation of the furnace and associated apparatus showing one of the combustion chambers, one of the roastingchambers and the alloying furnace in section.

Fig. 2 is an end elevation of the superstructure and furnace with a portion of the apparatus omitted for clarity.

Fig. 3 is a sectional elevation of the alloying furnace on a plane at right angles to Fig. 1.

Fig. 4. is a plan of the alloying furnace and connections.

Fig. 5 is a lateral section of one of the roasting chambers and its associated draft chamber on the line m -50, Fig. 1.

Fig. 6 is an enlarged sectional elevation of the condensing and separating apparatus on the line ac -x Fig. 7.

Fig. 7 is a plan of the condensing and separating apparatus.

Fig. 8 is a fragmentary section of the dead oil conveyer nozzle.

Fig. 9 is a lateral sectional elevation of one of the separators.

Fig. 10 is an enlarged plan of one of the combustion chambers showing the retort connections.

Fig. 11 is a sectional elevation of Fig. 10 on the line E 1? Fig. 12 is a sectional plan of the Same on the line :c :r

Similar reference numerals indicate the same parts throughout the specifications and the several views of the drawings.

Reference is had to a patent granted to me by the United States, bearing the Number 891,630, and the date of June 23, 1908, in which certain 'other improvements in smelting furnaces are shown.

In order that my process may be more fully understood, I will describe the functions and operation of the plant by means of which my process is carried out.

The combustion chambers 1 are shown in the drawings as being square, but they may be round, or of any' other suitable shape, are preferably vertical, and have a plurality of sub-chambers 2 on each of the sides arranged at an angle of about 45 degrees and provided with the fuel injectors or burners 3 adapted for connection to a plurality of pipes 4 for supplying steam, liquid fuel, oxygen and hydrogen for combustion in the chambers 1, and these pipes are adapted to be connected to a steam, fuel and gas supply source.

The chambers 1 are lined with fire brick or other refractory substance 5, have a metallic outer wall 6, and are provided at the bottom with suitable outlets 7, by means of which the metals or substances smelted or refined may be discharged from the furnace. The inclosures 8 are connected at their lower ends with the chambers 1 and inclined at an angle of about 45 degrees therefrom, have a metallic outer wall and refractory lining similar to the chambers 1, and are subdivided into two chambers 9 and 10 separated by the grate 11, the upper portion of the inclosure forming a smelting chamber 9, and the lower portion forming a draft chamber 10. These inclosures are provided with a lateral partition 12, as shown in Figs. 1 and 5, which extends across the chamber 10 a distance equal to about the width of the smelting chamber 9, and passages 13 are provided at the sides of this partition above and below the grates to al low the draft to rise through the grates and lap over the top of the, chamber 9, the passages 13 being closed at suitable points by an extension 13 of the partition 12.

The grates 11 are composed of tubes which terminate in the water boxes lei at the outside of the inclosure 8, and are so arranged that a complete circulation of the water may be had at all times through the tubes, the water being supplied to the tubes by means of the pumps 15 connected with the tubes by the pipes 16. The grate tubes are connected by the hinged and jointed pipes 17 to a water gate 18 positioned at the lower end of the smelting chambers 9, and this gate is divided into two compartments by a central partition or baflie plate 19 having an opening 20 at the bottom for affording communication between the compartments, and the water from the grates is caused to circulate through the compartments in the gate and thence into the water tanks 21 which are positioned on the structure of the plant above the level of the gate 18 and the grate 11, so' that in the event of a sudden stoppage of the pumps. 15, the gate and grates may be supplied with water from the tanks, and may not therefore become dry and subject to bursting from overheating.

The grates are adapted to be revolved or agitated constantly by a suitable mechanism,

not shown, in order that the ore which rests upon them may be kept constantly under agitation and the heat from the combustion chambers thus allowed to penetrate the voids between the particles of ore. The circulation of the water through the grates and the water gates of the smelting chambers, in addition to preventing their becoming overheated, also, as the water becomes heated in its passage through the grate tubes of the grate 11', supplies steam to the steam drums 22 at right angles to and positioned above thewater tanks 21, the steam being conducted from the grate tubes 11 through the pipes 23 and 24 to the drums, and by means of the necks 25 which connect the steam drums'22 with the water tanks 21, the steam which may rise from the water in the tanks is also admitted to the drums,

a supply of dry steam being thus supplied for use in the operation of the plant.

When the plant is being run as a smelter, the gates 18 are lowered so as to close the smelting chambers at their lower ends and thus prevent the ores from falling into the mon center and having a stack combustion chambers 1, but when the plant is run as a refining plant, the gates may be opened so that the metals or substances may be deposited in the bottom of the chambers 1 and from there drawn oif into suitable receptacles, the operation of the gates being accomplished by means of the steam cylinders 26 suitably connected to the gates by the rods 27 and also to the steam drums 22 from which the steam is supplied for oper ating the cylinders,

The smelting chambers 9 are charged with ore or substance through the hoppers 28 at the upper ends of the chambers, and these hoppers may be made as shown, or, the hoppers being provided at their junction with the chambers 9, with suitable gates 29 hav ing a refractory lining and adapted to be operated by steam cylinders similar to those used to operate the gates 18, and additional gates may be placed in the hoppers at convenient points if necessary, to keep out the air from the chambers 9.

My entire plant .is mounted upon a superstructure 30 composed of I beams and channels suitably braced and supported, and at the top of the structure I place the fuel tanks 31 and the water tanks 32, the fuel and water being supplied to the tanks by means of a battery of pumps suitably arranged and interconnected, so that in the event that one or more of the pumps should, for any reason, he inoperative, any one or number of the remaining pumps in the battery may be utilized to supply the tanks with fuel or water.

In the illustrations, only two of theunits are shown in the plant, each unit consisting of one of the combustion chambers 1 and its associated inclosure 8, but any number of these units may be used in a plant that may be found convenient, the units being arranged at equal intervals around a com- 33 which is common to all of the units, and the stack being provided with a vent 33 having a suitable safety damper in the top for allowing the escape of an oversupply of gases.

The stack 33 is connected with a condenser 34 which'is located at one side of the plant and which is composed of a vertical shell 35 having a metallic outer wall 36 and a refractory lining 37. In the center of the shell 35 is journaled the vertical shaft 38, on the upper end of which is the ordinary ball overnor 39, and below the governor, at the top of the shell 35 and secured to the shaft 38 is the valve actuating plate 40.

The upper portion of the condenseris provided with an inlet 41 to which the stack 33, from the furnace is connected, and revolubly mounted in the condenser and in a suitable cylinder 42 secured to the walls of the condenser shell 35, is a helical vaned water cylthe tanks and the pump,

inder 43, conical in shape, and mounted at the top on the roller bearings 44, and at the bottom on the ball bearings 45, the bearings at both the top and bottom being revolubly mounted on the stationary cylinder 42. The water cylinder 43 is adapted to fit snugly in the stationary be driven by water admitted through the pipe 46 in the side of the shell 35, directed against the vanes of the water wheel, the pipe 46 being connected with the water tanks 32 and by means of the pipe 47 with a pump, and the valves 48 being suitably interposed between the supply pipes from so that a water supply may be obtained from either source.

The governor 39 has a sleeve 49 which is slidable on the vertical shaft 38, the shaft is provided with a spring 50 adapted to compress between the revolving plate 40 and the lower end of the sleeve 49, and the sleeve has an annular groove 51 in which is seated one end of a lever 52 formed into a yoke and whose outer end is pivoted to a bracket 52 secured to the upper end of the condenser shell 35, the extreme outer end of the lever 52 being pivoted to a vertical link 53 which is connected, by means of the lever 54 and the arm 55, with the water supply valve 56, so that at the instance of the governor 39, the water supply 'may be controlled by the speed of the water cylinder 43.

- The shaft 38 is provided with an induction fan 57 adapted to rotate and positioned in the upper end of the condenser shell 35 just below the inlet 41 for drawing the mixture from the stack 33 into the lower compartments of the condenser through the water cylinder 43 which has a skeleton ribbed top and bottom to admit of the passage of the mixture therethrough. The funnel 58 is secured to the bottom of the cylinder 42 and the water discharged from the vanes 59 of the cylinder 43 is caused to spread against the sides of this funnel and form a sheet of water through which the mixture is caused to pass. The cooling of the gases in this process causes certain of them which have comparatively high condensing points to separate from the mixture, and these are drawn downwardly.

The condenser shell 35 is provided with an outlet 60 at the top, to which is connected the pipe 61 leading to an induction fan 62, and the fan 62 is connected by the pipes 63 and 64 with a series of retorts 65 arranged in the lining of the combustion chambers 1 in close proximity to the chambers 1 so that they may be subjected to the heat generated therein, and these retorts are so connected at the top and bottom by the pipes 66 and the Ts 67 as to form a continuous passage of several lengths for the gases. The upper end of the retort passage is connected with cylinder 42 and tothe compartments. The inner ends of the separators are connected at the tops with the bottom of the condenser shell 35 by the pipes 77 having the valves 78-,- and the outer ends vof the separators are connected with the dead oil tanks 79 by the pipes 80 having the valves 81 seated in the tops of the pipes and adapted to be operated by the vertical rods 82.

The vacuum tubes 83 extend down into the inner ends of the separators 75 to a point considerably below the normal water level in the compartments, and they are provided with pipes 84 by which they are connected with the vacuum chambers 98 in the condenser, and in their upper portions they are provided with the conical valves 85 having the valve stems 86. The tubes 83 are divided into two compartments, 98 being the lower compartment in which a vacuum is maintained, and the upper chamber having the draft pipes 91, which are connected with the stack 33 at convenient distances apart. The valve stems 86 are provided with the pistons 87 and the springs 88 adapted to compress between the pistons 87 i and the cap 89.0f the tubes 83, and these stems are pivotedat their upper ends to the cranks 92 on the outer ends of the longitudinal shafts 93 which are revolubly mounted in the brackets 94 secured to the top of the condenser shell 35. The inner ends of the shafts 98 are provided with the cams 95 which are adapted to engage intermittently the upwardly extending inclined segments 96 on the top of the valve actuating plate 40 which are so arranged that some one of the cams 95 will always be in engagement with one of the segments, the action of the cams servin to open and close the valves 85 in the tu es 83, and by the arrangement of the segments 96 as just described, will create a perpetual draft in the stack.

The funnel 97 is secured in the condenser shell 35, is somewhat larger than the funnel 58 and completely surrounds it, thus forming the vacuum chamber 98 between the two funnels, the suction of the water created by the centrifugal spreader cylinder 43 serving to withdraw the air from the chamber 98 and also, by means of the pipe 84: from the chamber 98' in the tubes 83. The liquids formed by the condensation of the gases from the stack and the mixture with the water of the heavier substances in the condenser is discharged from the condenser, by

rators 75, and this liquid rises in the compartments of the separator to a point just high enough to allow a circulation over the tops of the baflies 76, and a certain amount of the liquid will also rise in the bottom of the tubes 83 and register the amount of vacuum in the chambers 98' to which a suitable gage'may be connected for visibly indicatmg the amount of vacuum in the tubes. The circulation of the liquids over and under the baflies 76 in the separators causes an agitation of the particles of solid matter in the liquid and prevents a settling of the sediment in the bottoms of the separators. In each of the compartments between the bafiies 76, I suspend a plurality of electroplates 99 on the hooks 100 secured to ordinary spring balances 101, as shown in Fig. 9, and the plates are connected by the wires 102 to battery cells or other source of electric current, so that an electrolytic action on the particles of the finer metals is had, the particles accumulated on the plates and their values Weighed on the spring balances from which the plates 99 are suspended.

The residue tanks 79 are provided at the gravity through the pipes 77 into the sepabottoms with a small longitudinal and semi cylindrical compartment 103 which opens into the tanks and in which is revolubly mounted a conveyer 104 on a shaft 105, the latter being suitably connected by gears or belt with a source of power, and the forward,

end of the compartment 103 being provided with a nozzle 106 which is separated from the tanks 79 by a partition 107 having a plurality of perforations, not shown, so that, as the sediment which accumulates in the compartment 103 at the bottom of the tanks, is conveyed into the nozzle 106 form, the liquid will be forced in a compact through the perforations into the tanks and thus separated from the solid matter.

Between the tanks 79, I provide a briqueting machine of a common variety, but

adapted to suit the conditions of my plant,-

which is composed of a vertical shaft 108 journaled in a stationary disk 109 centrally positioned between the tanks 79, extending under the ends of the nozzles 106 and having the perforations 110; a pair of rollers 111 revolubly mounted on the arms 112 pivoted on the shaft 108 and adapted to register with the perforations 110 in the disk 109; the cam 113 secured to the shaft 108 and adapted to engage and operate intermittently the lever 11% which is pivoted near one end to the bracket 115 secured to the structure 30 and having a yoke 116 at the other end adapted to engage a pin 117 in the head of the plunger 118 which is vertically slidable in an extension 119 on the disk 109; and a spring 120 adapted to compress between the head of the plunger 118 and the extension 119 on the disk.

The sediment from the conveyer 104 is discharged from the nozzle 106 and deposited upon the disk 109 over the perforations 110, the rollers 111 revolve over-the sediment and press it into the perforations 110, thus forming it into briquets, and the plungers, after the rollers have passed from over the perforations, are forced down through the perforations 110 by the action of the cam 113 and the lever 114, and the briquets are deposited on a suitable conveyer belt 121 beneath the disk 109, by which they may be carried to any desired point and stored for further. treatment. The shaft 108 is provided below the disk 109, with a pair of pulleys 122 which are connected with and driven by the belts 123 from the pulleys 124 on a countershaft. The water from the tanks 79 is withdrawn therefrom and forced through the pipes 125 by the pumps 126 back to the water tanks 32 when it may be used again in the operation of the plant.

My alloying apparatus, as shown in Figs. 1,2 and 3, has a furnace with a' central chamber 127 surrounded by a refractory inner wall 128 and an outer metallic wall 129, has the fuel injector chambers 130and the injectors 131, respectively similar to those in the chamber 1. The furnace isprovided with a central cylinder 132 secured in the top of the furnace, communicating with the chamber 127 and projecting down into this chamber for a short distance. The cylinder 132 has a valve 133 in its top which serves as a means of escape for certain combustible gases which, may rise from the chamber 127 into the cylinder during an alloying operation. The furnace is provided with the metal inlets 134 at the sides which are adapted to be connected by the pipes 135 and the sleeves 136 with the outlets 7 of the chambers 1, by means of which the metal from the smelter may be admitted tothe alloying furnace. The entire furnace and its connections is mounted upon a truck 137 having wheels 138 adapted to run on a track 139 beneath the structure 30 and extending outwardly therefrom for a convenient distance to a casting pit 139, as shown in Fig. 4, where the metal from the alloy furnace in its pure or alloyed state may be discharged through the pipes 143 and the bars of bullion cast in a vacuum supplied by means of the battery of pumps 141 and the pipes 142 extending into the pit for withdrawing the air. A plurality of gas tanks 140 are arranged on each side of and secured to the truck 137, in which a supply of the necessary gases for the fuel injectors may be kept, and from the tanks supplied to the injectors, the arrangement described serving to maintain a portable supply of elements essential to the operatlon of the furnace, and by the connection of the pipes 142 with the casting pit 139, the

bars of bullion are rendered free from air I holes and defects in the casting process.

When the plant is being run as a smelter, the alloying furnace may, or may not, be used, and if not the pipe connections 135 which. are temporary, may be disconnected, and the metal from the chambers 1 runoff into any suitable receptacle; but when in use, the metal will flow from the chamber 1 into the chamber 127, and at stated intervals, the inlets may be closed, and the truck 137 run out upon the track 139 close to the pit 139, and the metal discharged therefrom and disposed of as hereinbefore described. The flow of the metal from the chambers 1 may be so regulated that a certain amount of one kind of metal will be supplied from one of the chambers 1- and the required amounts of other metals from other of the chambers 1, so that definite proportions may be had in the preparation of any alloy. Ordinarily when only one kind of metal is being extracted from its ore, the metalwill be drawn off into crucibles, and the alloying furnace will not be used, in which case it may be disconnected from the chambers 1 and rolled out of the way.

In carrying out my process, after a supply of water and fuel has been supplied to the tanks 31 and 32, the fuel and gases may be turned into the injectors 3, and a combustion established by saturating a piece of waste in oil, lighting it and placing it in the chambers 1. The heat and gases from the combustion of the fuels rise through the inclosures 8, circulate between the grate tubes 11 and the chambers 9 and 10, heat the water being circulated in the grate tubes and the water gates 18, and thus supply steam to the drums 22. The grates 11 are set in motion by applying steam to the grate actuating mechanism, the gates in the hoppers are opened, the gates 18 in the roasting chambers 9 are closed, and the chambers 9 are charged with ore through the hoppers 28.

The metals may be extracted, one at a time from the raw ores in all of the furnaces by regulating the heat in all of the combustion chambers 1 to a uniform temperature which corresponds to the melting point of the metal it is desired to extract; or, in the event that a different grade of ore is placed in each plant, or a different metal may be extracted from the ore in the different smelting chambers, the heat in each of the chambers 1 may be regulated to a' different temperature which corresponds to the melting point of the different metals it is desired to extract, and the metal will flow from the ore through the inclosures 8 between the grate tubes and fall into the mixture will be drawn through the pipes 61 and the fan 62 and forced through the series of retorts 65, where, by subjecting it to the-action of steam and liquid fuel which are injected through the small pipes 67 and 68' and superheatingit in its passage through the lining of the chamber 1, it becomes highly volatilized and a combustible gas varying in ingredients but composed principally of hydro-carbons is formed for use in the furnace, or otherwise, and is drawn through the pipes 72 and 73 and the fan 72 and forced into the gasometers 74, where it may be returned to the furnaces as needed, or supplied for other purposes. While the suction in the tubes 83, when the valves 85 are opened, will draw a certain amount of the mixture from the stack 33, and thence throughthe tubes 83 and the pipes 8a into the condenser 34:, the mixture from the stack is drawn downwardly through the; condenser by the fan 57 and similarly treated with water, will become somewhat cooled in the process, and as hereinbefore described will be discharged into the separators 75, Where it may be cooled and subjected to electrolytic action, the finer metals collected, the water drawn ofi and stored'in the tanks, and the sediment formed into briquets and stored away for further refinement.

In the operation of a plant of this character, it is frequently the case that certain combustible gases may accumulate in the top of the combustion chambers 1 which may be dangerous, but with my system of retorts as hereinbefore described, it is not possible for such a state of affairs to exist, when the retorts are operative, as the gases are kept in circulation. However, in order to provide against such a state, in the event that the retorts should for any reason hecome inoperative, I provide the vent 70 in the top of the chambers 1 which is connected to the retorts 65, through which the gases may rise under pressure and from thence through the pipes 72 and 73 until the force of the gases is expended, and the danger of explosions in the chambers 1 averted.

Having thus described my invention What I claim as new and desire Letters Patent for is: i

l. The hereindescribed process consisting of smelting ore, drawing off the liberated gases, passing the mixture into a condenser whereby a portion is condensed, drawing off the condensed portion, drawing'ofi the remaining gases from the condenser, superheating same and returning them to the smelting chamber.

2. The hereindescribed process consisting of smelting ore, drawing off the liberated gases, passing the mixture into a condenser whereby a portion is condensed, drawing off the condensed portion and separating it into its constituent products, drawing ofl the remaining gases from the condenser, superheatlng same and returning them to the smelting chamber.

FREDERICK L. MoGAI-IAN. 

